TWI Digital Library

Friction stir welding (FSW) experiments were undertaken on sheet specimens (thickness 4 mm) of AISI 304 stainless steel (17.5-19.5%Cr, 8-10.5%Ni) using different uncoated and coated tungsten and WC-based tools, and tool wear and failure mechanisms w…

A friction stir spot welding process variant was evaluated, which was intended to remove the hole left in the weld when the probe is removed, and consequently improve weld properties. In the two-step procedure, first a backing plate was used that ha…

Friction stir welding (FSW) was employed to fabricate hybrid joints between wrought AA 5454 aluminium alloys and AZ 91 die cast magnesium alloys, and the weldability, microstructure, mechanical properties, corrosion and fracture behaviour of the wel…

Conventional friction stir welding (FSW), hybrid FSW and thermal stir welding were evaluated and compared for the joining of a nickel-based superalloy Haynes 230. Welds were made in Haynes 230 NiCrW alloy (20-24%Cr, 13-15%W, 6.4 mm thickness), an in…

Defects and their mitigation associated with the fabrication of fluid-cooled aluminium alloy heatsinks for electronic applications are discussed. The heatsink consisted of an aluminium alloy 6063 substrate (310 x 300 mm) with a series of rectangular…

Arcan tests (pure tensile, pure shear and mixed tensile/shear loads) were performed on parent material (6056-T78 aluminium alloy) and friction stir welded (FSW) specimens for comparison purposes and to assess the capability of strain field measureme…

Stationary shoulder friction stir welding (SSFSW) and conventional FSW experiments were undertaken on AA 7050-T7651 alloy plates (thickness 6.3 mm) to demonstrate the advantages of SSFSW with respect to surface finish, thermal profile symmetry, HAZ …

An experimental and numerical analysis of the wear of a polycrystalline boron nitride (PCBN) friction stir welding (FSW) tool is overviewed as presentation slides. Topics highlighted include: FSW plunge trials of EH46 shipbuilding steel at a plunge …

A friction stir welding (FSW) methodology incorporating laser tracking and constant force control technologies was developed in order to fabricate large, thin-walled aircraft floor structures. The material chosen for study comprised sheet specimens …

A series of models was used to study weld formation in 6000-series aluminium alloy in the friction stir welding process. Weld formation was considered as three separate thermomechanical processes: coupled friction heat generation; plastic flow slip …

A thermal-pseudo-mechanical model, based on the use of material temperature-dependent yield stress as the driver for heat input, was proposed for heat generation in friction stir welding, and simulation results were compared with experimental temper…

A two-step modelling procedure, consisting of a thermo-fluid model and a thermo-mechanical model, was employed to predict temperature, flow and residual stress fields around the workpiece block, steel backing plate and tool in friction stir welding …

An economic analysis was undertaken to compare the costs of onshore and offshore pipeline construction scenarios for welds made using friction stir welding (FSW) and conventional mechanised MIG/MAG welding. Pipe diameters of 1067 and 305 mm were sel…

The feasibility of friction stir welding TIMETAL 21S beta titanium in the annealed condition was investigated. The composition of the alloy is Ti, 14-16%Mo, 2.4-3.2%Nb, 2.5-3.5%Al, 0.15-0.25%Si, max.0.4%Fe, 0.11-0.17%O, max.0.05%C, max.0.05%N, max.0…

An algorithm and procedure for controlling process zone temperature during friction stir processing are presented. The approach is based on the correlation between weld zone temperature with spindle power. A simplified thermal balance model of the w…

With regard to the need for in-process subsurface defect monitoring during friction stir welding (FSW) of aluminium alloys, an investigation is presented into a real-time force measurement system of process output to sense defect formation. Issues d…

An experimental investigation was made on the effect of processing variables and tool material on the microstructure of friction stir welded (FSW) 6 mm thick HSLA-65 steel plate, with the aim of optimising the process variables for enhanced mechanic…

Friction stir spot welded joints in aluminium alloy 6061-T4 were studied. Sheet of 1, 1.5, 2, and 3 mm thickness was friction stir welded to sheet of 3 mm thickness, using welds of 8-18 mm in length (equivalent in area to circular resistance spot we…

Friction stir welding (FSW) is a solid-state welding process, particularly suitable for aluminum alloys. The process allows the production of welds with a high seam strength and low distortion. Despite these benefits, irregularities can occur during…

Thermodynamic modelling and experimental measurements were employed to investigate the influence of intermetallic compound formation on the shear strength of dissimilar joints between an aluminium alloy and ultra-high strength steel fabricated by fr…